Device for controlling the strength of an extractable beverage

ABSTRACT

Processes for controlling strength of an extracted beverage including providing a pseudo packed bed of an extractable beverage material and contacting at least one liquid extraction stream with the pseudo packed bed of beverage material at a selected depth to obtain at least one zone of minimum extraction and at least one zone of maximum extraction. As the depth at which the liquid extraction stream is introduced into the packed bed increases, the zone of minimum extraction increases and the zone of maximum extraction decreases.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of, claims priority to, and any otherbenefit of U.S. patent application Ser. No. 11/431,464, filed on May 10,2006, entitled “PROCESSES FOR CONTROLLING THE STRENGTH OF AN EXTRACTABLEBEVERAGE,” now U.S. Pat. No. 7,815,955, which claims priority to and anyother benefit of U.S. Provisional Application Ser. No. 60/752,249, filedon Dec. 19, 2005, the entire disclosures of which are all herebyincorporated by reference herein.

FIELD OF THE INVENTION

Exemplary embodiments of the present invention generally relate toprocesses for controlling the strength of an extractable beverage.

BACKGROUND OF THE INVENTION

Today's coffee savvy consumers can be quite particular about the waythey prefer their coffee. Whether it is a skinny latte or a double shotespresso, consumers know what they want and expect it to be available tothem when they want it.

While driving to the corner coffee shop is certainly one way forconsumers to get their coffee as they wish, we live in a fast-paced,convenience-oriented society that often doesn't allow for the timeneeded to drive to the coffee shop, only to have to wait in line topurchase the desired beverage. Moreover, coffee house beverages areoften too pricey for the average consumer to indulge in on a regularbasis. Thus, in an effort to save both time and money, many consumersopt to prepare their coffee beverages at home.

Until recently, the only option available to consumers who wanted tobrew their coffee at home was a conventional multi-cup brewing device.However, the recent development of single-cup brewing devices has openedup a new door for consumers wanting to brew only one cup of coffee at atime.

Single-cup brewing devices are designed to quickly brew a fresh cup ofroast and ground coffee. Such systems allow the consumer to rapidly makean individual cup of coffee, rather than brewing an entire pot andwasting a portion of it if only a single cup is desired. Because of suchfeatures, many consumers prefer the ease and convenience of using one ofthe various single-cup brewing devices currently on the market. However,while single-cup brewing devices may offer the convenience consumers arelooking for, such brewing devices can present unique challenges toconsumer controlled brewing, and in particular, to the consumer'sability to control the strength of the coffee (e.g. strength control).

Strength control can be an important consideration for coffee drinkers.One reason many consumers drink coffee is because of the caffeinecontent, which can help them start their day awake and alert. However,individual consumers react to caffeine consumption in different ways.While one consumer may need a significant amount of caffeine (i.e.strong coffee beverage) to feel alert, another consumer may only need toconsume a small amount of caffeine (i.e. mild coffee beverage) toexperience the same effect, and indeed, may feel jittery and shaky iftoo much caffeine is consumed. In this respect, it is desirable toprovide a way for consumers to control the strength of their coffeebeverages.

Another reason many consumers drink coffee is because they enjoy thetaste. However, some coffee drinkers have underlying health concerns,such as acid reflux or indigestion, which can restrict the strength ofthe coffee they can comfortably consume. Again, it is thereforedesirable to give consumers the ability to control the strength of theircoffee.

The aforementioned strength control challenges often associated withsingle-cup brewing devices largely relate to the fact that single-cupbrewing devices typically brew only prepackaged pods or cartridgescontaining a predetermined amount of coffee product. This packagingarrangement can prevent consumers from readily adjusting the strength oftheir coffee.

For instance, unlike standard multi-cup brewing devices, single-cupbrewing devices use a predetermined amount of water to brew thebeverages. Thus, if a consumer selects that he desires an 8 oz. cup ofcoffee, the single-cup brewing device is programmed to use roughly 8 oz.of water to extract and prepare the beverage. Thus, the consumer is notable to select a “mild” or “strong” 8 oz. cup of coffee. The consumermust accept the predetermined beverage strength programmed into thebrewing devices, which is usually a moderate strength, and which may notbe acceptable to all consumers.

Furthermore, as previously mentioned, most single-cup brewing devicescurrently on the market work in conjunction with pods or cartridges thatcontain a predetermined amount of extractable beverage material. Onceagain, there is little the consumer can do to alter the strength of thebrewed beverage and must brew the predetermined amount of coffee presentin the pod.

While these two factors are designed to make brewing a single cup ofcoffee easier and more convenient for the consumer, they caninadvertently make it more difficult for the consumer to brew a beveragehaving the strength he desires. Thus, to date, consumers who want theconvenience of using a single-cup brewing device may have to sacrificethe ability to control the strength of their beverage.

Therefore, it is desirable to devise a process for producing a beveragethat provides consumers with the ease and convenience of single-cupbrewing without compromising the desired strength.

SUMMARY OF THE INVENTION

Exemplary embodiments of the present invention generally relate toprocesses for controlling the strength of an extractable beverage.

In particular, in one exemplary embodiment, the present inventiongenerally relates to providing a pseudo packed bed of an extractablebeverage material and contacting at least one liquid extraction streamwith the pseudo packed bed of extractable beverage material at aselected depth to obtain at least one zone of minimum extraction and atleast one zone of maximum extraction wherein as the depth at which theliquid extraction stream contacts the pseudo packed bed increases, thezone of minimum extraction increases and the zone of maximum extractiondecreases.

In another exemplary embodiment, the present invention generally relatesto providing a pseudo packed bed of an extractable beverage material andcontacting at least one liquid extraction stream having a selectedcoverage area with the pseudo packed bed of beverage material to obtainat least one zone of minimum extraction and at least one zone of maximumextraction wherein as the coverage area of the liquid extraction streamincreases, the zone of minimum extraction decreases and the zone ofmaximum extraction increases.

In still another exemplary embodiment, the present invention generallyrelates to providing a pseudo packed bed of an extractable beveragematerial and contacting at least one liquid extraction stream having aselected coverage area with the pseudo packed bed at a selected depth toobtain at least one zone of minimum extraction and at least one zone ofmaximum extraction wherein as the coverage area of the liquid extractionstream increases, the zone of minimum extraction decreases and the zoneof maximum extraction increases and wherein as the depth at which theliquid extraction stream contacts the pseudo packed bed increases, thezone of minimum extraction increases and the zone of maximum extractiondecreases.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a schematic perspective view of one embodiment of an articlefor containing an extractable beverage material in accordance withexemplary embodiments of the present invention.

FIG. 1B is a schematic perspective view of an alternate embodiment of anarticle for containing an extractable beverage material in accordancewith exemplary embodiments of the present invention.

FIG. 2A is a schematic cross-sectional view FIG. 1A along line A-A.

FIG. 2B is a schematic cross-sectional view of FIG. 1B along line X-X.

FIG. 3 is a schematic cross-sectional view of one embodiment of anarticle having a liquid extraction stream oriented to an averagestrength depth in accordance with exemplary embodiments of the presentinvention.

FIG. 4 is a schematic cross-sectional view of one embodiment of anarticle having a liquid extraction stream oriented to a mild strengthdepth in accordance with exemplary embodiments of the present invention.

FIG. 5 is a schematic cross-sectional view of one embodiment of anarticle having a liquid extraction stream oriented to an averagestrength coverage area in accordance with exemplary embodiments of thepresent invention.

FIG. 6 is a schematic cross-sectional view of one embodiment of anarticle having a liquid extraction stream oriented to a strong strengthcoverage area in accordance with exemplary embodiments of the presentinvention.

FIG. 7 is a schematic cross-sectional view of one embodiment of anarticle having a liquid extraction stream oriented to a mild strengthdepth and coverage area in accordance with exemplary embodiments of thepresent invention.

FIG. 8 is a schematic cross-sectional view of an alternate embodiment ofan article having a liquid extraction stream oriented to a mild strengthdepth and coverage area in accordance with exemplary embodiments of thepresent invention.

FIG. 9 is a schematic cross-sectional view of one embodiment of anarticle having multiple liquid extraction streams in accordance withexemplary embodiments of the present invention.

DETAILED DESCRIPTION OF THE INVENTION A. Definitions

As used herein, the term “area” means internal space inside of anarticle that may be occupied by a pseudo packed bed of extractablebeverage material. Area may be determined by the dimensions of thearticle. In addition to the pseudo packed bed, the area may also beoccupied by a minimal void or headspace.

As used herein, the term “article[s]” means any package capable ofcontaining a single serving of an extractable beverage material.Suitable articles for use herein, include, but are not limited to pods,cartridges and pouches, which may be flexible, rigid, semi-rigid, orcombinations thereof and may be constructed of such materials as paper,non-woven filter materials, foils, plastics and combinations thereof.

As used herein, the term “at least one” means that while there can beonly one, embodiments of the present invention need not be limited tosuch. For instance, there may be any number, such as two, three, four ormore. For example, while there may be at least one liquid extractionstream, there may be two, three, four or any number of liquid extractionstreams.

As used herein, the term “average” strength means the extracted beveragecomprises from about 0.50% to about 0.75% brew solids, and in oneembodiment about 0.60% brew solids, by weight of the extracted beverage.Additionally, an average strength extracted beverage can have a ratio ofthe zone of minimum extraction to the zone of maximum extraction of fromabout 0.20:1 to about 0.89:1, and in one embodiment about 0.5:1.

As used herein, the term “balanced” means that the beverage generallycomprises about equal amounts of the early and late eluting componentsand does not contain substantially more of one component than the other.The flavor of the extracted beverage is of a high-quality typical of afully-extracted coffee.

As used herein, the term “comprising” means various components can becojointly employed in the methods and articles of this invention.Accordingly, the terms “consisting essentially of” and “consisting of”are embodied in the term comprising.

As used herein, the term “contact” means a liquid extraction stream isin fluid communication with the pseudo packed bed of extractablebeverage materials such that extraction of the beverage materialsoccurs. Such contact can be direct (e.g. liquid extraction streamcontacts the pseudo packed bed of extractable beverage material) orindirect (e.g. liquid extraction stream passes through article prior tocontacting the pseudo packed bed of extractable beverage material).

As used herein, the term “coverage area” means a portion of the pseudopacked bed of extractable material within the article that can becontacted by at least one liquid extraction stream. The coverage areamay take any form, including, but not limited to, a spray, fan or jet.

As used herein, the term “depth” means the distance into the pseudopacked bed at which the liquid extraction stream contacts the pseudopacked bed of extractable beverage material.

As used herein, the term “extractable beverage material(s)” means anymaterial, and in one embodiment, plant material, which may be contactedwith the liquid extraction stream to produce consumable beverageextracts. Suitable extractable beverage materials for use hereininclude, but are not limited to, roast and ground coffee and ground tealeaves. Such materials may be in the form of, but not limited to, dryparticulates or powders.

As used herein, the term “extracted beverage(s)” or “extractablebeverage(s)” means a consumable beverage resulting from contactingextractable beverage materials with a liquid extraction stream.Extracted beverages herein may include coffee beverages, tea beveragesand the like.

As used herein, the term “fully extracted” means that substantially allof the water soluble solids of the extractable beverage material can besolubilized and removed in the targeted zone of maximum extractionleaving a mass of insoluble material in the article, when subjected totypical brewing conditions.

As used herein, the term “liquid extraction stream” means a fluid streamoriginating from a brewing device that can contact an article comprisingan extractable beverage material to produce an extracted beverage.Though in one embodiment there is at least one liquid extraction stream,it will be understood that there may be any number. Moreover, anyconventional brewing device liquid delivery mechanism may be used todistribute the liquid extraction stream such that it may contact thearticle, and more particularly, the substantially packed bed ofextractable material. For instance, a nozzle or showerhead may be usedto spray the liquid extraction stream onto the article to contact theextractable beverage material or, optionally, a piercing member may beused to introduce the liquid extraction stream into the article where itmay contact the extractable beverage material.

As used herein, the term “mild” strength means the extracted beveragecomprises less than about 0.50% brew solids, and in one embodiment fromabout 0.35% to about 0.49% brew solids, and in another embodiment about0.40% brew solids, by weight of the extracted beverage. Additionally, amild strength extracted beverage can have a ratio of the zone of minimumextraction to the zone of maximum extraction of from about 0.90:1 toabout 2.3:1, and in one embodiment about 1.2:1.

As used herein, the term “overall strength” means the strength of theextracted beverage regardless of the number, depth and/or coverage areaof the liquid extraction stream(s).

As used herein, the term “strong” strength means that the extractedbeverage comprises at least about 0.76% to about 0.95% brew solids, inone embodiment about 0.80% brew solids, and in another embodiment about0.85% brew solids, by weight of the extracted beverage. Additionally, astrong strength extracted beverage can have a ratio of the zone ofminimum extraction to the zone of maximum extraction of from about0.19:1 to about 0.01:1, and in one embodiment about 0.05:1.

As used herein, the terms “pseudo packed bed” and “pseudo packed bedenvironment” are used interchangeably to mean that extractable beveragematerial may be substantially fixed prior to contact with a liquidextraction stream, such that the extractable beverage material issignificantly restricted in movement in all directions within thearticle. Under pseudo packed-bed conditions, free movement of theparticles of the extractable beverage material may be reduced, such thatparticles located in the static zone(s) of minimum extraction may behindered from entering into the dynamic zone(s) of maximum extraction.It is expected that particles within the maximum extraction zone can bein a state of flux due to the movement and velocity of the mobile phase,which further facilitates extraction. The size and/or area of the pseudopacked bed can be defined by the dimensions of the article in which itis contained.

As used herein, the term “unextracted” refers to any portions of theextractable beverage material, and in particular to zones of minimumextraction, that may become wetted during the brew cycle due tocapillary action, back-mixing, flooding or combinations thereof, but arenot in constant contact with a liquid extraction stream, and thus, donot significantly contribute to the overall strength of the extractedbeverage.

As used herein, the term “zone of maximum extraction” refers to an areaof the pseudo packed bed of extractable materials wherein theextractable beverage materials may be fully extracted by constantcontact with the at least one liquid extraction stream throughout thebrew cycle.

As used herein, the term “zone of minimum extraction” refers to an areaof the pseudo packed bed in which the extractable beverage materialtherein is substantially unextracted. Zones of minimum extraction aregenerally further from the liquid extraction stream, and more static,than the zones of maximum extraction. Therefore, zones of minimumextraction are not constantly contacted by a liquid extraction streamthroughout the brew cycle and do not do not significantly contribute tothe overall strength of the extracted beverage.

It will be understood that when referring to the drawings, like numeralsdesignate like parts throughout the various views.

B. Processes

Exemplary embodiments of the present invention generally relate toprocesses for controlling the strength of an extractable beverage. Asaforementioned, today's consumers enjoy the ease and convenience ofsingle-cup brewing devices, yet still desire the ability to customizebeverage strength to meet their dietary and taste preferences.Embodiments disclosed herein can aid in satisfying these consumer needsby providing processes that can give the consumer the ability to alterthe strength of a prepackaged extractable beverage.

Embodiments of the present processes are designed for use withextractable beverage materials. As defined herein, “extractable beveragematerial(s)” includes roast and ground coffee, ground tea leaves andother similar plant-based materials, which may be contacted with aliquid, such as water, to produce consumable extracts. Such materialsmay be in the form of, but are not limited to, dry particulates and/orpowders. In one embodiment, the extractable beverage material may have aparticle size of from about 300 microns to about 500 microns while inanother embodiment, the extractable beverage material may have aparticle size of about 400 microns. Furthermore, as used herein,“extracted beverage(s)” means the consumable beverage resulting fromcontacting the extractable beverage materials with liquid and includecoffee beverages, tea beverages and the like. While the followingdescription will focus on roast and ground coffee and coffee beveragesextracted with water, those skilled in the art will understand that thisis for illustration purposes only and the present invention should notbe limited thereto.

Extractable beverage materials herein may be packaged in individualserving sized articles, such as, but not limited to, pods, cartridges orpouches for use in single-cup brewing devices. FIGS. 1A and 1B depicttwo exemplary embodiments of articles in accordance with the presentinvention. As shown in FIG. 1A, article 10 may generally comprise a body12, a bottom 13 and a closure 14. Article 10, and more specifically,body 12, bottom 13 and closure 14, may be flexible or rigid and may beconstructed of such materials as paper, non-woven filter materials,foils, and plastics, as well as combinations thereof. Additionally, thearticles herein may come in a variety of configurations. For instance,in one embodiment, article 10 may be a deep cup-shaped container, likethat shown in FIG. 1A, and may optionally comprise a water impermeablebody 12 and water permeable bottom 13 and closure 14. Such aconfiguration may help to ensure proper extraction by directing a liquidthrough article 10 and out bottom 13 rather than out through body 12. Inanother embodiment, as shown in FIG. 1B, article 110 may be asubstantially flat pouch in which body 112, bottom 113 and closure 114may all be comprised of filter paper material. Regardless of whichconfiguration is chosen, the articles herein can contain an individualserving of extractable beverage material for use in conjunction withsingle-cup brewing devices. Moreover, the articles may be designed suchthat the extractable beverage material can be retained and preventedfrom exiting the article along with the extracted beverage. This may beaccomplished by using filter paper, or other like material, as thebottom of the article. Those skilled in the art will understand how toconstruct such articles to satisfy the previously described desirablefeatures.

As discussed above, single-cup brewing devices can present uniquechallenges to consumer controlled brewing, and in particular, tostrength control. Embodiments of the present processes can address thesechallenges by allowing the consumer to control one or more aspects ofthe brewing process, thereby controlling the strength of the beverage.

In conventional brewing processes, the coffee grounds used to brewcoffee can be loose or loosely packed to allow a maximum area of thecoffee particles to come into contact with water during the extractionprocess. This can help ensure that the extract produced during brewingis rich in extractable material, thereby providing a beverage having abalanced taste. The notion of loosely packing the particles may beespecially true for the pods and cartridges used in single-cup brewingdevices, which tend to have empty head space between the top of thecoffee particles and the closure to allow the coffee particles to freelyshift about. Because of the rapid brew cycle of single-cup brewingdevices, it can be important that the maximum amount of extractablematerial is exposed to the extraction liquid in order to help ensure thefinished beverage has the desired quality characteristics.

In contrast to the loosely-packed pods and cartridges currently on themarket, exemplary articles herein may comprise a pseudo packed bed ofextractable beverage material (16 in FIG. 2A and 116 in FIG. 2B). Asdefined herein, “pseudo packed bed” or “pseudo packed bed environment”means the extractable beverage material may be substantially fixed priorto contact with a liquid extraction stream, such that the extractablebeverage material is significantly restricted in movement in alldirections within the article. The size and/or area of the pseudo packedbed can be defined by the dimensions of the article in which it iscontained. The pseudo packed bed can be designed such that, in oneembodiment, there is substantially no void or headspace between theextractable beverage material and the article closure. In anotherembodiment, there may be a minimal void between the extractable beveragematerial and the article closure. For example, in one embodiment, thevoid (15 in FIG. 2A and 115 in FIG. 2B) may account for less than about10% of the area of the article, while in another embodiment, the voidmay account for less than about 5%, and in still another embodiment lessthan about 2%, and in yet another embodiment less than about 1%, and instill another embodiment less than about 0.5%, and in yet anotherembodiment less than about 0.1%, of the area of the article.Additionally, the extractable beverage material may be fashioned into apseudo packed bed as the article is assembled or the pseudo packed bedmay result from the compression of the extractable material once thearticle is placed into a brewing device.

For example, roasted and ground coffee can comprise a range of particlesizes with each particle having its own unique morphology that canprovide a degree of randomness to the pseudo packed bed environment. Theindividual particles' ability to pack, as well as the interspacesbetween the particles, can allow a pseudo-packed bed to be easilycreated by filling the article to substantial completeness (to fill mostof the volume of an article with extractable material) i.e. in oneembodiment from about 65% to about 99%, in another embodiment from about80% to about 97%, and in yet another embodiment from about 85% to about95% of the area of the article. Particle to particle interactions of asubstantially filled article can restrict particle movement, especiallyin zones of minimum extraction, discussed later herein, where there islow velocity fluid movement. Thus, a pseudo packed bed environment canprevent the particles of the extractable beverage material from movingfreely about, thereby providing consistency in beverage strength andflavor. Without being limited by theory, it is believed that thesubstantially static zones of minimum extraction may be slower toextract due to achieving a state of near-equilibrium with the mobilephase (water), as compared to the more turbulent and dynamic mobilephase present within zones of maximum extraction. It will be understoodby those skilled in the art that the pseudo packed bed environment maychange as the brewing cycle progresses since under dynamic extractionconditions other physical parameters may become influential (e.g.swelling of the extractable material, elongation of the filter media dueto temperature and pressure, etc.) such that by the end of the brewcycle there may be some limited degree of movement of the particles ofthe extractable beverage material.

As illustrated in FIG. 3, once the pseudo packed bed of extractablebeverage material 16 is obtained, at least one liquid extraction stream20 can be brought into contact with pseudo packed bed 16. As usedherein, the term “contact” means that the liquid extraction stream is influid communication with the pseudo packed bed of extractable beveragematerials such that extraction of the beverage materials begins. Suchcontact can be direct or indirect. While in one embodiment, liquidextraction stream 20 can comprise water, it should not be limited tosuch. Moreover, liquid extraction stream 20 may be brought into contactwith article 10 by way of a nozzle 22, showerhead, or other likeassembly, which can be part of a beverage brewing device. Those skilledin the art will understand how to use various conventional brewingdevice liquid delivery mechanisms in conjunction with the processesdescribed herein. In one embodiment, the nozzle or showerhead may spraythe liquid extraction stream through at least one orifice and onto theclosure of the article, thereby resulting in indirect contact with thepseudo packed bed of extractable beverage material. In this instance, itmay be desired to position the nozzle or showerhead adjacent to, and incontact with, the closure of the article to minimize splash-back and/orrun-off of the liquid extraction stream. In another embodiment, and asshown in FIG. 3, nozzle 22 may puncture, pierce or be otherwise capableof entering article 10, and more specifically, the pseudo packed bed ofextractable beverage materials 16 such that liquid extraction stream 20can directly contact the pseudo packed bed of extractable beveragematerials 16 via at least one orifice in nozzle 22. As will be explainedlater herein, liquid extraction stream 20 may take any of a variety offorms including, but not limited to, a spray, a fan or jet.Substantially all of water used to prepare the beverage may be directedinto and through the pod for use in extracting the beverage materialstherein (i.e., none of the water used to extract the beverage materialsintentionally bypasses the article). This can help ensure that thebeverage materials are fully extracted to provide a balanced beverage.Those skilled in the art will understand that both the velocity at whichthe liquid extraction stream exits nozzle or showerhead, as well as theshape of any orifices present in the nozzle or showerhead, can have aneffect on the form of the liquid extraction stream. For example, to helpmaintain the desired zones of minimum and maximum extraction, in oneembodiment, the flow rate at which the liquid extraction stream entersand extracted beverage exits the article may be about the same.Temperature of the liquid extraction stream may also affect theextractability of the beverage material and thus, the quality of theextracted beverage. While the temperature of the liquid extractionstream may vary from one brewing device to another, the expectation isthat the extracted beverage will have a temperature and qualityacceptable to consumers.

Upon introduction of the liquid extraction stream 20 into pseudo packedbed 16, liquid extraction stream 20 can provide at least one zone ofminimum extraction 24 and at least one zone of maximum extraction 26. Asused presently, “zone of maximum extraction” refers to an area of thepseudo packed bed of extractable materials wherein the extractablebeverage materials may be fully extracted by constant contact with theat least one liquid extraction stream throughout the brew cycle. Asexplained herein below, the size and number of zones of maximumextraction can help determine the yield of soluble solids from theextractable material.

“Zone of minimum extraction” refers to an area of the pseudo packed bedin which the extractable beverage material therein is substantiallyunextracted. Zones of minimum extraction are generally further from theliquid extraction stream and more static than the zones of maximumextraction. Therefore, zones of minimum extraction are generally not inconstant contact with a liquid extraction stream throughout the brewcycle and, therefore, do not significantly contribute to the overallstrength of the extracted beverage.

The size of the zones of maximum extraction and minimum extraction canvary depending on the desired beverage strength. For instance, a“strong” beverage as defined herein can comprise from about 0.76% toabout 0.95% brew solids and in one embodiment at least about 0.80% brewsolids, and in yet another embodiment at least about 0.85%, brew solids,by weight of the extracted beverage. An “average” beverage as definedherein can comprise from about 0.50% to about 0.75% brew solids, and inone embodiment about 0.60% brew solids, by weight of the extractedbeverage. A “mild” beverage as defined herein can comprise less thanabout 0.50% brew solids, and in one embodiment from about 0.35% to about0.49% brew solids, and in yet another embodiment about 0.40% brewsolids, by weight of the extracted beverage. Brew solids content may bedetermined using any conventional technique known to those skilled inthe art.

In general, the zone of maximum extraction may account for from about0.01% to about 99.99% of the pseudo packed bed. If a strong beverage isdesired, the zone of maximum extraction may account for from about 84%to about 99.9%, and in another embodiment from about 91.8% to about99.7%, of the pseudo packed bed. If an average beverage is desired, thezone of maximum extraction may account for from about 53% to about 83%,and in another embodiment from about 62% to about 73%, of the pseudopacked bed. If a mild beverage is desired, the zone of maximumextraction may account for from about 30% to about 52%, and in anotherembodiment from about 39% to about 50%, of the pseudo packed bed.

Similarly, the zone of minimum extraction may account for from about0.01% to about 99.9% of the pseudo packed bed. If a strong beverage isdesired, the zone of minimum extraction may account for from about 0.01%to about 16%, and in another embodiment from about 0.03% to about 8.2%,of the pseudo packed bed. If an average beverage is desired, the zone ofminimum extraction may account for from about 17% to about 47%, and inanother embodiment from about 27% to about 38%, of the pseudo packedbed. If a mild beverage is desired, the zone of minimum extraction mayaccount for from about 48% to about 70%, and in another embodiment fromabout 50% to about 61%, of the pseudo packed bed.

In view of the above, it can be said that the ratio of the zone ofminimum extraction to the zone of maximum extraction may be from about0.19:1 to about 0.01:1, and in one embodiment about 0.05:1, for a strongbeverage, from about 0.2:1 to about 0.89:1, and in one embodiment about0.5:1 for an average beverage and from about 0.90 to about 2.3:1, and inone embodiment about 1.2:1 for a mild beverage.

It will be understood by those skilled in the art that the foregoing“strong,” “average” and “mild” strengths are based on US consumers'taste preferences, and thus, in other regions of the world the definedvalues of the foregoing characteristics may differ from those set forthherein. It will also be understood by those skilled in the art that, ingeneral, the greater the zone of maximum extraction, the smaller thezone of minimum extraction, and the stronger the extracted beverage.Conversely, the greater the zone of minimum extraction, the smaller thezone of maximum extraction, the milder the extracted beverage.

Within each zone of maximum extraction, the coffee can be fullyextracted and balanced. As used herein, “fully extracted” means thatsubstantially all of the water soluble solids in the extractablebeverage material within the targeted zone of maximum extraction can besolubilized and removed from the remaining mass of insoluble matter,when subjected to typical brewing temperatures. “Balanced” means thatthe flavor of the extracted beverage is of a high-quality typical of afully-extracted coffee. The fraction eluted during the first half of anextract from a given portion of coffee tends to comprise sweetcompounds. By itself, this initial fraction produces an unbalanced cupof coffee. In contrast, the fraction eluted during the final half of anextraction tends to comprise compounds that are bitter. Again, alone,this final fraction produces an unbalanced cup of coffee. However, whenthese fractions are combined, the sweet and bitter compounds blendtogether to produce a balanced cup of coffee. Thus, the flavor of a“balanced” beverage generally comprises about equal amounts of both theearly and late eluting components and does not contain substantiallymore of one component than the other. A surprising aspect of the presentinvention is that a reduced strength beverage having a balanced flavor,can consistently be prepared from an article that is capable ofproviding more strength or brew solids, simply by altering the ratio ofthe zones of minimum and maximum extraction within the pseudo-packedbed. Conventional coffee brewing processes generally cannot achieve areduced strength beverage having a balanced flavor without reducing theamount of coffee used, as shifting of the loosely packed coffeeparticles during the brew cycle tends to result in a substantially evenextraction of all of the beverage materials. Attempts to use less waterby bypassing at least a portion of the water around the pod can producea lower strength beverage but such a beverage may likely have anunbalanced flavor, or watered down taste, since the coffee is not fullyextracted.

Though embodiments of the present processes may be applied in a varietyof ways, as described in detail herein below, regardless of theapplication, the processes can remedy the foregoing known extractiondifficulties of prepackaged articles and provide a fully extracted,balanced coffee beverage having the strength desired by the consumer.This is made possible by the use of the pseudo packed bed environment,which, as previously described, can restrict movement and shifting ofthe coffee particles and help ensure that the targeted zone of maximumextraction remains substantially fixed throughout the brew cycle.

One exemplary embodiment of the present processes comprises providing apseudo packed bed of an extractable beverage material; contacting atleast one liquid extraction stream with the pseudo packed bed ofbeverage material at a selected depth to obtain at least one zone ofminimum extraction and at least one zone of maximum extraction, whereinas the depth at which the liquid extraction stream contacts the packedbed increases, the zone of minimum extraction increases and the zone ofmaximum extraction decreases.

In the foregoing embodiment, it is the depth at which the liquidextraction stream contacts the pseudo packed bed of beverage materialthat dictates the strength of the extracted beverage. As used herein,and as illustrated in FIG. 3, “depth” D of liquid extraction stream 20refers to the distance into the pseudo packed bed 16 at which the liquidextraction stream contacts the pseudo packed bed of extractable beveragematerial 16. In one embodiment, and as shown in FIG. 3, liquidextraction stream 20 may be introduced into article 10, and contactpseudo packed bed 16, via nozzle 22. In this particular embodiment,nozzle 22 can have a piercing member having one or more orifices throughwhich to distribute liquid extraction stream 20 throughout pseudo packedbed 16, thereby creating zone of minimum extraction 24 and zone ofmaximum extraction 26. It is intended that the consumer can control thedepth of the liquid extraction stream by any conventional brewing devicecontrol mechanism known to those skilled in the art, such as, forexample, a dial or button selector or lever that allows the consumer toselect the depth of the liquid extraction stream, and therefore, thestrength, of the beverage desired.

Manipulating depth D of liquid extraction stream 20 can alter thestrength of the extracted beverage because different depths cancorrelate to different sized zones of maximum and minimum extraction.For instance, introducing liquid extraction stream 20 about one thirdthe way into pseudo packed bed 16, as shown in FIG. 3, can provide anaverage strength beverage because the ratio of minimum to maximum zonesof extraction would be about 0.5:1 thus leading to the aforementionedbrew solids content of from about 0.50% to about 0.75%. Therefore,because about 67% of the extractable beverage material contained withinarticle 10 is fully extracted, the beverage strength is about average.

Similarly, the depth of the liquid extraction stream may also becontrolled to produce a mild or strong beverage by altering theplacement of the liquid extraction streams. More specifically, as shownin FIG. 4, a mild beverage may be obtained by positioning liquidextraction stream 20 to a substantial depth D′ within pseudo packed bed16, which results in a small zone of maximum extraction 26 and a largezone of minimum extraction 24. Because a lesser percentage of theextractable beverage materials are fully extracted, the resultingbeverage is mild. Conversely, a strong beverage may be obtained bypositioning the liquid extraction stream to a shallow depth within thepseudo packed bed, which can result in a large zone of maximumextraction and a small zone of minimum extraction. Because a greaterpercentage of the extractable beverage materials are fully extracted,the resulting beverage is strong.

In a second exemplary embodiment of the present invention, the presentprocesses can comprise providing a pseudo packed bed of an extractablebeverage material, contacting at least one liquid extraction streamhaving a selected coverage area with the pseudo packed bed of beveragematerial to obtain at least one zone of minimum extraction and at leastone zone of maximum extraction, wherein as the coverage area of theliquid extraction stream increases, the zone of minimum extractiondecreases and the zone of maximum extraction increases.

In this second exemplary embodiment, and as illustrated in FIG. 5, it isthe coverage area A of liquid extraction stream 120 when it contactspseudo packed bed of extractable beverage material 116 that can dictatethe strength of the extracted beverage. As used herein, the “coveragearea” means the portion of the pseudo packed bed of extractable materialwithin the article that can be contacted by the at least one liquidextraction stream. As previously mentioned, the liquid extraction streammay take any variety of forms, including, but not limited to, a spray, afan or a jet. Similar to depth, coverage area of the liquid extractionstream may be controlled by the consumer by way of any conventionalbrewing device control mechanism known to those skilled in the art, suchas, for example, a dial or button selector or lever that allows theconsumer to select the coverage area of the liquid extraction stream,and therefore, the strength, of the beverage desired. In one exemplaryembodiment, coverage area may be altered by manipulating the velocity atwhich the liquid extraction stream exits the nozzle or showerhead. Inanother exemplary embodiment, coverage area may be altered bymanipulating the size of the orifices present in the nozzle orshowerhead.

Controlling the coverage area of the liquid extraction stream can alterthe strength of the beverage because different coverage areas cancorrelate to different sized zones of maximum and minimum extraction.For instance, liquid extraction stream 120, having a coverage area A inthe form of a fan, as shown in FIG. 5, could be used to provide anaverage strength beverage because the ratio of the zone of minimumextraction 124 to the zone of maximum extraction 126 would be about0.5:1, thus leading to a brew solids content of about 0.50% to about0.75%.

Similarly, the coverage area of the liquid extraction stream may becontrolled to produce a mild or strong beverage by adjusting the size ofthe coverage area of the liquid extraction stream. More specifically, amild beverage may be selected by introducing a liquid extraction streamhaving a coverage area in the form of a narrow jet, which results in asmall zone of maximum extraction and a large zone of minimum extraction.Because a lesser percentage of the extractable beverage materials arefully extracted, the resulting beverage is mild. Conversely, as shown inFIG. 6, a strong beverage may be selected by contacting a liquidextraction stream 20 having a coverage area A in the form of a broadspray, with the pseudo packed bed 16. This can result in a large zone ofmaximum extraction 26 and a small zone of minimum extraction 24. Becausea greater percentage of the extractable beverage materials are fullyextracted, the resulting beverage is strong.

A third exemplary embodiment of the present invention is illustrated inFIG. 7 and generally relates to processes that combine the twopreviously described embodiments. In this particular embodiment, theprocesses comprise providing a pseudo packed bed of an extractablebeverage material, and contacting at least one liquid extraction streamhaving a selected coverage area with the pseudo packed bed at a selecteddepth to obtain at least one zone of minimum extraction and at least onezone of maximum extraction, wherein as the coverage area of the liquidextraction stream increases, the zone of minimum extraction decreasesand the zone of maximum extraction increases and wherein as the depth atwhich the liquid extraction stream contacts the pseudo packed bedincreases, the zone of minimum extraction increases and the zone ofmaximum extraction decreases.

In this third exemplary embodiment, it is both the depth at which theliquid extraction stream contacts the pseudo packed bed, as well ascoverage area of the liquid extraction stream when it contacts thepseudo packed bed, which can dictate the strength of the extractedbeverage. For instance, as shown in FIGS. 7 and 8, a mild strengthbeverage can be produced in at least two different ways. FIG. 7illustrates liquid extraction stream 20 in the form of a jet having anarrow coverage area A* contacting pseudo packed bed 16 at a shallowdepth D*. This can provide a ratio of the zone of minimum extraction 24to the zone of maximum extraction 26 of about 1.2:1. Likewise, asillustrated in FIG. 8, a liquid extraction stream 20 in the form of ajet having a broad coverage area A** may contact pseudo packed bed 16 ata substantial Depth D**, or about two-thirds of the way, into pseudopacked bed 16 to also provide a ratio of the zone of minimum extraction24 to the zone of maximum extraction 26 of about 1.2:1. As shown inFIGS. 7 and 8, different depths and coverage areas may be combined innumerous ways to produce a mild strength extracted beverage. Thoseskilled in the art will understand how the depth and coverage area ofthe liquid extraction stream may be manipulated to provide beverageshaving different strengths.

Additionally, it should be noted that for any embodiment of the presentinvention, including those described above, there should be at least oneliquid extraction stream, but the present process need not be limited toonly one liquid extraction stream. There may be any number of liquidextraction streams, such as two, three or four. As a result, there mayalso be any number of zones of maximum extraction, as well as any numberof zones of minimum extraction, though, in one embodiment, there is atleast one of each. To reflect this notion, and as defined herein, theterm “at least one,” as used in references to the liquid extractionstream and/or the zones of extraction, encompasses two, three, four orany number of liquid extraction streams and/or zones of extractionunless specifically designated otherwise. For example, as shown in FIG.9, article 110 may be contacted by two liquid extraction streams, 120and 120′, to increase the area of pseudo packed bed 116 that can befully extracted, thereby increasing the overall strength of theextracted beverage.

As will be understood by those skilled in the art, regardless of theparticular embodiment employed, as the number of liquid extractionstreams increases, the overall strength of the extracted beverageincreases. This is because as the number of liquid extraction streamsincreases, the number, and therefore the collective size, of the zonesof maximum extraction also increases. Moreover, it should be noted thatin situations where there is more than one liquid extraction streampresent, the multiple streams need not be identical. Each liquidextraction stream may be positioned to the same or differing depths andhave the same of differing coverage areas. More particularly, oneextraction stream may be a jet injected halfway into the pseudo packedbed while a second stream is in the form of a broad sprayed introducedat a shallow depth into the pseudo packed bed. Each zone of maximumextraction will occupy a different area of the pseudo packed bed, thoughsuch areas may overlap, but the overall strength of the extractedbeverage will be stronger than it would have been with each of the zonesof maximum extraction individually.

EXAMPLES Example 1

A coffee pod is prepared for use in a single cup brewing device. Thesingle-use pod resembles a thin-walled plastic cup and has an internalcapacity of about 26.5 cc and a depth of about 1.25 inches (3.2 cm), asmeasured from the bottom of the pod to where a closure will be attached.The cup is filled substantially to capacity with about 9.5 grams ofroast & ground coffee having a mean particle size distribution of about400 microns, thereby creating a substantially packed bed of extractablebeverage material (i.e. coffee). A non-woven polymeric filter paper (JRCrompton LTD.) is heat sealed to the cup as a closure, thus containingthe coffee grounds. A consumer inverts the pod and places it into abrewing device manufactured to brew the pod at either a strong, average,or mild brew strength. The water reservoir of the brewing device isfilled with the necessary amount of water and a cup is positioned toreceive the extracted coffee. The consumer, desiring a beverage having a“strong” strength, selects a strong beverage by turning a dial on thebrewing device to a preset “strong” position and pressing the startbutton. The brew cycle is initiated and the brewing device pushes anapproximately 3/32 inch (2.38 mm) I.D. tubular shaped nozzle having a20° acute angle into what is now the top of the pod. The nozzle entersthe pseudo packed bed of extractable beverage material at a depth ofabout 0.187 inches (4.75 mm). Hot water passes through the nozzle at arate of about 5.0 cc/second at a temperature of about 185° F. (85 C) forabout 55 seconds. About 266 grams of extracted coffee is collected intothe consumer's cup. The extracted coffee has a strong strength andbalanced flavor and is determined to contain about 0.85% brew solids.

Example 2

A coffee pod is prepared and placed into a brewing device as in Example1 above. The consumer, desiring a beverage having an average strength,selects an “average” beverage by turning a dial on the brewing device toa preset “average” position and pressing the start button. The brewcycle is initiated and the brewing device pushes an approximately 3/32inch (2.38 mm) I.D. tubular shaped nozzle having a 20° acute angle intowhat is now the top of the pod. The nozzle enters the pseudo packed bedof extractable beverage material at a depth of about 0.50 inches (12.7mm) as measured from the center of the orifices to the pod closure. Hotwater at a temperature of about 185° F. (85 C) passes through the nozzlefor about 55 seconds, at a rate of about 5.0 cc/second produces avelocity of about 112 cm/second. About 266 grams of extracted coffee iscollected into the consumer's cup. The extracted coffee has an averagestrength and balanced flavor and is determined to contain about 0.60%brew solids.

Example 3

A coffee pod is prepared and placed into a brewing device as in Example1 above. The consumer, desiring a beverage having a “mild” strength,selects a mild beverage by turning a dial on the brewing device to apreset “mild” position and pressing the start button. The brew cycle isinitiated and the brewing device pushes an approximately 3/32 inch (2.38mm) I.D. tubular shaped nozzle having a 20° acute angle into what is nowthe top of the pod. The nozzle enters the substantially packed bed ofextractable beverage material at a depth of about 0.50 inches (12.7 mm).Hot water at a temperature of about 185° F. (85 C) passes through thenozzle for about 41 seconds, at a rate of about 6.5 cc/second produces avelocity of about 146 cm/second. About 266 grams of extracted coffee iscollected into the consumer's cup. The extracted coffee has a mildstrength and balanced flavor and is determined to contain about 0.45%brew solids.

Example 4

A coffee pod is prepared and placed into a brewing device as in Example1 above. The consumer, desiring a beverage having an “average” strength,selects an average beverage by pressing a preset “average” button on thebrewing device followed by pressing the start button. The brew cycle isinitiated and the brewing device pushes into what is now the top of thepod an approximately 1/16 in (1.59 mm) I.D. tubular shaped nozzle intothe pod as opposed to its 3/32 inch (2.38 mm) I.D. tubular shaped nozzlehaving a 20° acute angle which produces a broad coverage area. Thenozzle enters the substantially packed bed of extractable beveragematerial at a depth of about 0.10 inches (2.54 mm). Hot water passesthrough the nozzle at a rate of about 5.0 cc/second at a temperature ofabout 185° F. (85 C) for about 55 seconds. About 266 grams of extractedcoffee is collected into the consumer's cup. The extracted coffee has anaverage strength and balanced flavor and is determined to contain about0.75% brew solids.

Example 5

A coffee pod is prepared and placed into a brewing device as in Example1 above. The consumer, desiring a beverage having a “average” strength,selects an average beverage setting by moving a lever on the brewingdevice to a preset “average” position, and the start button is pressed.The brew cycle is initiated and the brewing device pushes an articulatedtubular shaped nozzle capable of changing its orifice in graduationsfrom approximately 1/16 inch (1.59 mm) I.D., to approximately 3/32 inch(2.38 mm) I.D., to approximately ⅛ inch (3.175 mm) I.D., to a fullopening of approximately 5/32 inch (3.97 mm) I.D. nozzle into what isnow the top of the pod. At the average setting, the brewer adjusts thenozzle from the previous orifice setting, to an orifice of ⅛ inch (3.175mm) I.D., and the nozzle enters the substantially packed bed ofextractable beverage material at a depth of 0.50 inches (12.7 mm). Hotwater passes through the nozzle at a rate of about 5.0 cc/second at atemperature of about 185° F. (85 C) for about 55 seconds. About 266grams of extracted coffee is collected into the consumer's cup. Theextracted coffee has an average strength and balanced flavor and isdetermined to contain about 0.725% brew solids.

Example 6

A flat pod, similar to that shown in FIG. 1B, is constructed from anon-woven material. The pod has a compartment diameter of approximately2.375 inches, a body of approximately 0.3125 inches and is filled withabout 9.5 grams of roast and ground coffee having a mean particle sizedistribution of about 400 microns, thereby creating a pseudo packed bedof extractable beverage material (i.e. coffee). The consumer places thepod into a brewing device manufactured to brew the pod at either astrong, average, or mild brew strength. The brewing device is closed andwithin the brewer, a showerhead of substantially the same diameter asthe pod positioned adjacent to and in contact with the closure of thepod, thereby holding it secure. Three water inlet holes are spatiallylocated in the showerhead to provide full coverage of the pod by thewater. On the other side of the showerhead is another disk having holesthat selectively allow communication to the holes in the showerheadthrough rotation of the disk. A control knob used by the consumer toselect the beverage strength is affixed to the disk. By rotation of theknob, the disk is rotated internally within the brewer which allows one,two, or all three holes in the showerhead to be used for brewing the podto produce a mild, average, or strong strength beverage respectively.With a selection of mild, only one hole is in communication with thepod. The start button is pressed and water from the reservoir is heatedby the brewer and pumped through the one hole in the showerhead and intothe pod, and the extracted beverage is collected in a cup after exitingthe brewer. The extracted coffee has a mild strength and balanced flavorand contains about 0.40% coffee brew solids.

All documents cited in the present specification are, in relevant part,incorporated herein by reference; the citation of any document is not tobe construed as an admission that it is prior art with respect to thepresent invention.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

1. An improved brewing device for producing an adjustable strengthsingle serving of coffee, the improvement comprising: a. a single-servecoffee pod comprising a deep cup-shaped container substantially filledwith roast and ground coffee particles, wherein the cup-shaped containercomprises a water impermeable body and a water permeable bottom attachedto the body to retain the roast and ground coffee particles within thecup-shaped container, and wherein placing the coffee pod in the brewingdevice compresses the roast and ground coffee particles into apseudo-backed bed of roast and ground coffee particles; b. a nozzlehaving at least one orifice, wherein the nozzle is capable ofpenetrating the single-serve coffee pod and introducing at least oneliquid extraction stream into the single serve coffee pod in order toplace the liquid extraction stream into direct contact the pseudo packedbed of roast and ground coffee particles; and c. means for selectivelycontrolling depth of the nozzle penetration within the single-servecoffee pod, wherein controlling depth of nozzle penetration into thepseudo packed bed of roast and ground coffee particles provides controlover creation of a zone of minimum extraction and a zone of maximumextraction, and wherein in the size of the zone of maximum extractioncorrelates to the strength of single serving of coffee produced.
 2. Thebrewing device according claim 1, wherein the single-serve coffee pod isflexible, rigid, semi-rigid, or combinations thereof.
 3. The brewingdevice according claim 1, wherein the roast and ground coffee particlescomprise water soluble solids, and insoluble material which may be leftin the pod under typical brewing conditions.
 4. The brewing deviceaccording claim 1, wherein the roast and ground coffee particles have aparticle size of from about 300 microns to about 500 microns.
 5. Thebrewing device according claim 4, wherein the particle size is about 400microns.
 6. The brewing device according to claim 1, wherein the orificehas a shape that is capable of introducing the liquid extraction streaminto the single serve coffee pod in the form of a spray, a fan or a jet.7. The brewing device according to claim 1, wherein the means forselectively controlling depth of the nozzle penetration within thesingle-serve coffee pod comprises a dial, a button selector, or a lever.8. The brewing device according to claim 1, wherein the cup-shapedcontainer further comprises a closure sealed to the body to retain theroast and ground coffee particles within the cup-shaped container. 9.The brewing device according claim 8, wherein there is substantially novoid or headspace between the roast and ground coffee particles and theclosure sealed to the body.
 10. The brewing device according claim 8,wherein there is a void or headspace between the roast and ground coffeeparticles and the closure sealed to the body.
 11. The brewing deviceaccording claim 10, wherein the void or headspace accounts for less than10% of the size of the deep cup-shaped container.
 12. The brewing deviceaccording to claim 8, wherein the closure is constructed of paper,non-woven filter materials, foils, plastics, and combinations thereof.13. The brewing device according to claim 12, wherein the paper is anon-woven polymeric filter paper.
 14. The brewing device according toclaim 1, wherein the nozzle is a tubular shaped nozzle.
 15. The brewingdevice according to claim 14, wherein the tubular shaped nozzle has a90° angle relative to the top of the single-serve coffee pod.
 16. Thebrewing device according to claim 14, wherein the tubular shaped nozzlehas a 20° acute angle relative to the top of the single-serve coffeepod.
 17. The brewing device according to claim 1, wherein the internaldiameter (I.D.) of the orifice can be changed in graduations.
 18. Thebrewing device according to claim 17, wherein the internal diameter(I.D.) of the orifice can be changed in graduations from approximately1/16 inch (1.59 mm) to approximately 5/32 inch (3.97 mm).